Electrical apparatus comprising a wiring cast by extrusion



June 20, 1950 E. M. H. LIPS 2,512,152

ELECTRICAL APPARATUS COMPRISING A v WIRING CAST BY EXTRUSION Filed lay 2, 1947 .7 4 .6 i5 1/ .9 5 49 f f l I f EM. H. LIPS I NV NTOR ATTORNEY.

Patented June 20, 1950 ELECTRICAL APPARATUS COMPRISING A WIRING CAST BY EXC IRUSIO N Eduard mm minim Lips, Eindhoven, Netherlands, asslgnor to Hartford National Bank and Trust Company, Hartford, Conn., as trustee Application May 2, 1947, Serial No. 745,476 In the Netherlands June 18, 1946 3 Claims. 1

The invention relates to electrical apparatus, for example, radio-receiving apparatus, provided with a wiring formed, by means of an extrusion process, as one unit, on an insulating supporting plate to which it is secured. Component parts are mounted on this support by passing the ends of supply conductors which form part of these components through apertures provided in the insulating support, the ends protruding from these apertures being embedded in the material of the wiring. An apparatus of this type is known from French additional specification 50,893 to French specification 838,738.

In casting such a wiring diillculties are encountered due to the fact that, under the influence of the very high moulding pressure of several tens of atmospheres, the liquid casting material penetrates through the apertures along the supply wires of the components which pass through the apertures of the support, often damages the components and, after solidification, forms projections the removal of which results in supplementary costs and loss of time.

It might be endeavoured to avoid these diiliculties by ensuring an exact fit of the supply concase, however, it is very difilcult to introduce the supply conductors into the apertures, since these wires, due also to the tin coating, are never perfectly straight and smooth and, generally, cannot be introduced into the apertures exactly in the direction of the axis of the bore, so that they often get jammed in these apertures, which again results in loss of time and costs. A favourable compromise between these costs and those which are due to the penetration of the casting liquid through the apertures cannot be found either.

According to the invention, these difllculties are obviated by providing at least one insulating intermediate plate of materially les thickness than the support between the latter and the wiring, at least one supply conductor integral with a component being passed through an aperture in the intermediate plate, which aperture fits without clearance around the supply conductor and registers with an aperture of the support. A, for example circular, intermediate plate may be provided under each aperture of the support, although preferably use is made of a single intermediate plate which covers the whole of the support. Since the intermediate plate is much thinner than the support, the possibility of the supply wires getting jammed is greatly reduced and,

if this should occur, it will be readily possible inform the wires through the apertures in the materially thinner wall. It is even very well possible to utilize an intermediate plate of such small thickness that there is no need at all of providing beforehand apertures in it and to pierce the supplywires of the components through this thin plate, a highly satisfactory closure of the apertures by the supply conductors being thus naturally ensured.

The invention will now be described in connection with the drawing in which:

Fig. 1 shows a top view of the wiring arrangement;

Fig. 2 is a sectional view along the line IIII of Fig. l; and

Fig. 3 shows sectional view of a wiring arrangement wherein the component parts are arranged on opposite sides of the supporting base.

An insulating supporting plate I, for example. of moulding material or of hard paper, with a thickness of about 1 mm., exhibits two apertures I and 5, through which wire-shaped supply conductors I and 9 of a component, in the present case a condenser i I, are passed. In contact with the bottom-surface of the support i is provided an insulating intermediate plate ii, for example of hard paper, in which apertures I5 and I1 are provided which register with the apertures 3 and 5. The wires 1 and 9 also pass through the apertures i5 and il in which they fit without any clearance. This may be achieved by forcing the wires through the plate i3, which may have a thickness of from 0.05 to 0.04 mm. and which,

beforehand, is not provided with apertures.

The assembly formed by the two plates I and I3 is located in between the parts of a mould It and 2|. The top matrix I! is provided with an aperture 23 (cf. Fig. 1) to allow the passage of the component II. It is thus made possible to mount this component on the support prior to the introduction of the support I'into the mould, so that during the mounting the mould is not occupied.

The matrix 2| exhibits channel-like recesses 25 and 21 which may be brought into communication with a vessel containing molten moulding material and which, in the casting process, are filled with liquid metal. The wiring thus formed may be secured to the support by means of si-' multaneously cast rivets (not shown) in the manner as described in French Patent 838,738. As may be seen from Fig. 2, the metal embraces the ends of the supply wires I and 9 passing through the plates I and it, a conductive coning spurs which have to be removed afterwards,

which removal involves a great risk of damaging the wires 1 and 9.

Owing to the presence of the intermediate plate It, the diameters of the apertures 3 and I may be from 1 to 2 ms. larger than those of the supply wires, so that the wires can be passed through without the least dimculty. It is, how-' ever, also advantageous to make the diflerence in diameter smaller, for example 0.2 mm., it being thus ensured that the supply wires, which are, in this case, slightly jammed in the apertures, assist in securing the wiring (20,11) to the support.

In Fig. 3, the component parts II and 18 are mounted on opposite sides or support I provided with apertures for passing terminal leads of the component parts through the support. On both sides of the support are plates of insulating material II and I4 provided with apertures for passing the terminal leads through without clearance. The ends of the terminal leads are embedded in extruded die-cast conductors 22, 24,

a plate-shaped insulating supporting base with and 21, respectively, forming the wiring connections for the component parts.

What I claim is:

1. A wiring system for component parts of electrical apparatus having terminal leads forlestablishing electrical connections thereto comprising a plate-shaped insulating supporting base with suitably spaced apertures therein for passing the terminal leads of said component parts there- .flle of this patent:

clearance to prevent penetration of the wiretrical apparatus having terminal leads for estab lishing electrical connections thereto comprising suitably spaced apertures therein for passing the terminal leads 0! said component parts therethrough with clearance, a plurality of extruded wire conductors having enlarged terminal portions die-cast on opposite sides oi said supporting base, and an insulating plate having a thickness which is substantially less than one-half the thickness of said base between said wire conductors and said supporting base, said intermediate plate having apertures aligned with the apertures in said supporting base ior passing said terminal leads therethrough without clearance to prevent penetration of the wire conductor material during the die-casting process, said terminal leads being embedded in the terminal portions of said extruded conductors to establish electrical connections therewith.

3. A wiring system for component parts of electrical apparatus having terminal leads for establishing electrical connections thereto comprising a plate-shaped insulating supporting base with suitable spaced apertures therein for passing the terminal leads of said component parts therethrough with clearance, a plurality of extruded wire conductors having enlarged terminal portions die-cast on both sides of said supporting base, and an intermediate plate-shaped insulating member having a thickness which is substantially less than one-half the thickness of said base between said wire conductors and said supporting base in the region of each of said apertures, said intermediate member having apertures aligned with the apertures in said supporting base for passing said terminal leads therethrough without clearance to prevent penetration of the wire-conductor material during the diecasting process, said terminal leads being embedded in the terminal portions of said extruded conductors to establish electrical connections thereto.

- EDUARD MARIA HENRICUS LIPS.

REFERENCES CITED The following references are of record in the UNITED s'rs'ns ra'mn'rs Great Britain of 1900 

